Cable splice kit and method of use in making branchout service connections

ABSTRACT

A cable splice kit and method for providing a main distribution cable with service branchouts each including a separate auxiliary splice housing designed to be opened and reclosed while testing and servicing lead-in splicing operations without need for disturbing the main cable branchout splice. The branchout cable includes extra conductors spliced to the conductors of the main cable and available for connection to the lead-in cable when and as need arises. The branchout and service cables have electrical shields which are secured together in an area imbedded in potting compound at one end of the auxiliary splice housing.

United States Patent Inventors George W. Gillemot 2331 20th St., SantaMonica, Calif. 90405; John T. Thompson, 244 Laring St., Los Angeles,Calif. 90024 Appl. No. 864,065

Filed Oct. 6, 1969 Patented Oct. 19, 1971 CABLE SPLICE KIT AND METHOD OFUSE IN MAKING BRANCIIOUT SERVICE CONNECTIONS 8 Claims, 2 Drawing Figs.

u.s.c| 174/87, 156/48,174/76,174/93 1111. cr ..I-I02g l5/08, nouns/o0Field ofSearch 156/47,

[56] References Cited UNITED STATES PATENTS 3,209,069 9/1965 Ruddell eta1 174/76 3,309,456 3/1967 Connell 174/60 Primary Examiner-Benjamin A.Borchelt Assistant ExaminerI-I. Tudor Att0rneySellers and BraceABSTRACT: A cable splice kit and method for providing a maindistribution cable with service branchouts each including a separateauxiliary splice housing designed to be opened and reclosed whiletesting and servicing lead-in splicing operations without need fordisturbing the main cable branchout splice. The branchout cable includesextra conductors spliced to the conductors of the main cable andavailable for connection to the lead-in cable when and as need arises.The branchout and service cables have electrical shields which aresecured together in an area imbedded in potting compound at one end ofthe auxiliary splice housing.

CABLE SPLICE KIT AND METHOD OF USE IN MAKING BRANCI-IOUT SERVICECONNECTIONS This invention relates to cable splicing facilities and moreparticularly to an improved cable splice kit and method of use in makingbranchout connections to a main cable and featuring an auxiliary splicehousing which can be opened and closed repeatedly without risk of injuryto the main cable.

Telephone communication cables require branchout service connections atfrequent intervals with provision for testing and changing or increasingcommunication channels. Opening the main cable involves the serious riskof damage or the admission of moisture.

By this invention there is provided a technique for splicing a shortbranchout service cable to conductors of the main cable via apermanently sealed splice. The other end of branchout cable, togetherwith one end of a lead-in cable, is then sealed within one end of atwo-part auxiliary splice housing constructed for ready access. Theauxiliary splice comprises a pair of cup-shaped molded componentsarranged to be normally held together in telescoped assembly by aclamping band. The branchout and lead-in cables include electricalshielding secured in good conductive contact with one another by afitting imbedded in potting compound filling the housing half into whichthe two cables extend. The larger of the two housing parts is preferablymade of resilient nonconductive material and flexes readily tocompensate for pressure differentials across its sidewall.

Accordingly, it is a primary object of the present invention to providea cable splice kit and method for use in providing a main cable with ashort branchout service cable equipped at its outer end with anaccessible auxiliary splice.

Another object of the invention is the provision of a simple,inexpensive, reliable auxiliary splice housing for use between a maincable and a service lead-in cable which can be opened without hazard tothe main cable when testing and making splice connections.

Another object of the invention is the provision of a simply constructedcable splice assembly comprising a pair of sub units held detachablyassembled normally and readily separable to provide access to the spliceproper for testing and servlcmg.

These and other more specific objects will appear upon reading thefollowing specification and claims and upon considering in connectiontherewith the attached drawing to which they relate.

Referring now to the drawing in which a preferred embodiment of theinvention is illustrated:

FIG. 1 is a view showing a main cable equipped with the inventionbranchout and auxiliary splice facility; and

FIG. 2 is a cross-sectional view on an enlarged scale through theauxiliary splice per se.

Referring more particularly to FIG. I, there is shown a typicalinstallation of the invention comprising a main communication cablehaving a permanently sealed branchout cable splice 11 for a short lengthof branchout cable 12. Cable [2 usually comprises a plurality of pairsof conductors each permanently spliced to a selected conductor of maincable 10. Cable 12 is relatively short and projects into one end of theinvention auxiliary splice housing 14 closely beside a lead-in servicecable 15 sufficiently long to extend to the premises and equipment to beserviced.

Referring now to FIG. 2, it will be understood that auxiliary splicehousing 14 typically comprises two deep cup-shaped members 17, 18 ofsuitable nonconductive resilient material. As herein shown, the shorterhalf 17 is made in two parts including a short cylindrical length ofplastic tubing having a snug fit with a molded end cap 21. Members 20,21may be bonded together or the two parts can be molded in one piece ifdesired. The bottom of the cup-shaped member 17 is formed with twotubular bosses 22,23 sized to have a snug fit with branchout cable 12and lead-in cable 15.

The second cup-shaped half 18 of the splice housing has a snugtelescopic fit over the protruding end of tubular member 20 and isnormally held assembled thereto by a clamping band 25 of any suitableconstruction equipped with a threaded adjusting screw 26.

It will be understood that branchout cable 12 and lead-in cable 15include a plurality of pairs of conductors 28 enclosed by a sheath ofelectrical shielding 29,30 underlying an outer protective insulationsheath. It is important that the shielding layer of cables I2 and 15 besecurely anchored to one another in good electrical contact. This isreadily accomplished in the present invention using a bolt fastener ofthe type shown in FIG. 2. This fastener comprises a bolt 32 having adeeply slotted threaded shank 33 supporting a nut 34 having a knurledrim. It will be understood that the deep slot is sized to have a snugfit about electric shielding 29,30 of each of cables 12 and 15. A shortlength of the insulation of each of these cables is removed over an areaspaced rearwardly from the end of the insulation proper of these cables,as is clearly illustrated in FIG. 2. The cables are then assembled intothe bolt slot and nut 34 is tightened against the sheath of the adjacentone of the cables, thereby holding the two shields 29,30 pressedtogether between nut 34 and the inner end of the slot.

' Anchorage of the cables within splice housing half 17 is assured bycharging this housing member with potting compound 35. After completingthe assembly of fasteners 32, 34 cables 12 and 15 are pulled outwardlythrough bosses 22 and 23 a short distance until the fastener 32 islocated below the rim edge of member 17 and approximately in theposition shown in FIG. 2. Compound is then poured into member 17 whileheld upright and allowed to take a set. It will be understood that thepotting compound is of any suitable composition forming a strong bondwith the splice housing material and with the insulation of cables 12and 15.

The conductor pairs 28 of the two cables may be spliced together inconventional manner at any time. Usually only a part of the conductorsare spliced together, the remainder be- I hind held in reserve forfuture expansion needs. Auxiliary splice housing 14 is normallymaintained closed with the housing halves tightly clamped togetherexcept when testing and servicing the cables. To be noted is the factthat shielding 29,30 of each of the cables is exposed beyond the surfaceof potting compound 13 thereby facilitating checking the shield ing ofeach cable for continuity.

The auxiliary splice kit includes all the components illustrated in FIG.2 which are assembled in the manner described. Owing to the pliant andflexible character of the walls of housing member 18, splice facility 14readily compensates for pressure changes between the interior of thesplice and the ambient atmosphere. Accordingly, the pressure conditionsinteriorly of the housing remain in balance with those on the exteriorthereby greatly minimizing the sealing problem between components 17,18. Access to the auxiliary splice is obtained by the simple expedientof loosening clamping nut 26 of clamp 25 and then withdrawing the twohalves from their assembled position. After completing a servicingoperation the splice is recloscd and clamped in assembled position bytightening screw 26. As will be recognized, opening the auxiliary spliceimposes no risk on main cable 10. Nonnally, auxiliary splice I4 islocated closely adjacent the main cable for convenience in servicing thesplice without need for entering upon the customers property.

While the particular cable splice kit and method of use in makingbranchout service connections herein shown and disclosed in detail isfully capable of attaining the objects and providing the advantageshereinbefore stated, it is to be understood that it is merelyillustrative of the presently preferred embodiments of the invention.

We claim:

1. A cable splice assembly for use in providing an accessible protectiveenclosure for a splice between a pair of cables each having a pluralityof terminal ends of electrically shielded conductors, said assemblycomprising: a cup-shaped member of nonconductive material having a pairof port means in the bottom thereof and having a snug fit with each oneof a pair of shielded cables of conductors, an elongated tubular cap ofnonconductive material having one open end which has a snug telescopicfit with the exterior sidewall of said cup-shaped member, releasableclamp means detachably securing said cap in a fluid tight manner withthe side wall of said cup-shaped member, a threaded bolt of conductivematerial slotted lengthwise thereof and provided with a nut clamping anexposed length of the shielding of said pair of cables captive in saidslotted bolt, and a potting compound filling said cupshaped member to adepth substantially submerging said slotted bolt while leaving theterminal ends of said conductors accessible for splicing upon detachingsaid tubular cap from said cup-shaped member.

2. A reopenable splice assembly enclosing a pair of shielded electricalcables each having at least one pair of wires therein, said spliceassembly comprising first and second deep cupshaped members ofnonconductive material having their open ends telescoped snuglytogether, clamping means embracing the telescoped sections of said firstand second members and effective to hold the same detachably assembledin fluidtight manner, said first member having a plurality of tubularpassages each having a snug fit with a separate one of said shieldedcables inserted therethrough, a nut and a threaded slotted bolt ofconductive material assembled transversely of an exposed length ofshielding of a pair of shielded cables extending through said passagesin the bottom of said first cupshaped member clamping the shieldsthereof snugly against one another in an area spaced between theopposite ends of said first member, a potting compound substantiallyfilling said first member with the split bolt submerged therein andanchoring and sealing the cables in assembled position through thebottom of said first member, and the terminal ends of the cableconductors being housed within the second of said members and accessiblefor splicing and testing upon loosening said clamp and separating saidfirst and second members.

3. That method of providing a normally enclosed but accessible splicebetween a main cable of conductors provided with a series of serviceoutlets at intervals therealong without need for access to the maincable or risk of exposing the interior thereof to the elements, saidmethod comprising: providing a main cable at intervals with separatepermanently sealed splice assemblies each having a short length ofelectrically shielded branchout service cable extending therefrom,providing the free end of said shielded branchout shielded service cableand the adjacent end of a service lead-in cable with a normally closedbut openable fluidtight auxiliary splice housing formed in twocup-shaped halves sized to telescope over one another in opposedend-to-end relation, extending said branchout and lead-in cables throughthe bottom of one of said cup-shaped halves, securing the exposedshields of said cables in electrical contact with one another within theinterior of said one cup-shaped half, anchoring the portions of saidbranchout and lead-in cables immediately inside said one cupshaped halfin place therein with potting compound, and the terminal ends of saidbranchout and lead-in cables housed within the other of said cup-shapedhalves being exposed for splicing together and checking when the twohalves of said housing are separated.

4. That method defined in claim 3 characterized in the stp of normallysecuring the cup-shaped halves of said auxiliary housing telescopedtogether in a fluidtight manner.

5. That method defined in claim 3 characterized in the step of utilizinga soft pliant nonconductive composition for the half of said auxiliaryhousing enclosing the terminal ends of said branchout and lead-incables. i

6. That method defined in claim 3 characterized in utilizing arelatively short rigid housing half in combination with a relativelylong and pliant housing half the sidewalls of which flex and compensatefor small-range variations between internal and external pressure.

7. That method defined in claim 3 characterized in the step of securingsaid exposed shields together by seating the same against one another atthe inner end of an axially slotted bolt and tightening the bolt nutagainst said exposed cable shields,

and embedding said slotted bolt and the adjacent portions of the cablesclamped therein in said potting compound to safeguard the cable shieldsand to prevent the nut on said slotted bolt from loosening.

8. That method defined in claim 7 characterized in the steps oftelescoping the open ends of said cup-shaped housing halves together,and clamping the overlapping ends of said housing halves together in afluidtight manner with a clamping band located radially oppositeportions of said potting compound.

1. A cable splice assembly for use in providing an accessible protectiveenclosure for a splice between a pair of cables each having a pluralityof terminal ends of electrically shielded conductors, said assemblycomprising: a cup-shaped member of nonconductive material having a pairof port means in the bottom thereof and having a snug fit with each oneof a pair of shielded cables of conductors, an elongated tubular cap ofnonconductive material having one open end which has a snug telescopicfit with the exterior sidewall of said cup-shaped member, releasableclamp means detachably securing said cap in a fluid tight manner withthe side wall of said cup-shaped member, a threaded bolt of conductivematerial slotted lengthwise thereof and provided with a nut clamping anexposed length of the shielding of said pair of cables captive in saidslotted bolt, and a potting compound filling said cup-shaped member to adepth substantially submerging said slotted bolt while leaving theterminal ends of said conductors accessible for splicing upon detachingsaid tubular cap from said cup-shaped member.
 2. A reopenable spliceassembly enclosing a pair of shielded electrical cables each having atleast one pair of wires therein, said splice assembly comprising firstand second deep cup-shaped members of nonconductive material havingtheir open ends telescoped snugly together, clamping means embracing thetelescoped sections of said first and second members and effective tohold the same detachably assembled in fluidtight manner, said firstmember having a plurality of tubular passages each having a snug fitwith a separate one of said shielded cables inserted therethrough, a nutand a threaded slotted bolt of conductive material assembledtransversely of an exposed length of shielding of a pair of shieldedcables extending through said passages in the bottom of said firstcup-shaped member clamping the shields thereof snugly against oneanother in an area spaced between the opposite ends of said firstmember, a potting compound substantially filling said first member withthe split bolt submerged therein and anchoring and sealing the cables inassembled position through the bottom of said first member, and theterminal ends of the cable conductors being housed within the second ofsaid members and accessible for splicing and testing upon loosening saidclamp and separating said first and second members.
 3. That method ofproviding a normally enclosed but accessible splice between a main cableof conductors provided with a series of service outlets at intervalstherealong without need for access to the main cable or risk of exposingthe interior thereof to the elements, said method comprising: providinga main cable at intervals with separate permanently sealed spliceassemblies each having a short length of electrically shielded branchoutservice cable extending therefrom, providing the free end of saidshIelded branchout shielded service cable and the adjacent end of aservice lead-in cable with a normally closed but openable fluidtightauxiliary splice housing formed in two cup-shaped halves sized totelescope over one another in opposed end-to-end relation, extendingsaid branchout and lead-in cables through the bottom of one of saidcup-shaped halves, securing the exposed shields of said cables inelectrical contact with one another within the interior of said onecup-shaped half, anchoring the portions of said branchout and lead-incables immediately inside said one cup-shaped half in place therein withpotting compound, and the terminal ends of said branchout and lead-incables housed within the other of said cup-shaped halves being exposedfor splicing together and checking when the two halves of said housingare separated.
 4. That method defined in claim 3 characterized in thestp of normally securing the cup-shaped halves of said auxiliary housingtelescoped together in a fluidtight manner.
 5. That method defined inclaim 3 characterized in the step of utilizing a soft pliantnonconductive composition for the half of said auxiliary housingenclosing the terminal ends of said branchout and lead-in cables. 6.That method defined in claim 3 characterized in utilizing a relativelyshort rigid housing half in combination with a relatively long andpliant housing half the sidewalls of which flex and compensate forsmall-range variations between internal and external pressure.
 7. Thatmethod defined in claim 3 characterized in the step of securing saidexposed shields together by seating the same against one another at theinner end of an axially slotted bolt and tightening the bolt nut againstsaid exposed cable shields, and embedding said slotted bolt and theadjacent portions of the cables clamped therein in said potting compoundto safeguard the cable shields and to prevent the nut on said slottedbolt from loosening.
 8. That method defined in claim 7 characterized inthe steps of telescoping the open ends of said cup-shaped housing halvestogether, and clamping the overlapping ends of said housing halvestogether in a fluidtight manner with a clamping band located radiallyopposite portions of said potting compound.